Sign In
Upload
Manuals
Brands
PREVOST Manuals
Buses
X3-45 2016
PREVOST X3-45 2016 Manuals
Manuals and User Guides for PREVOST X3-45 2016. We have
1
PREVOST X3-45 2016 manual available for free PDF download: Maintenance Manual
PREVOST X3-45 2016 Maintenance Manual (459 pages)
Brand:
PREVOST
| Category:
Buses
| Size: 35 MB
Table of Contents
Table of Contents
5
Section 00: General Information
6
Foreword
6
Schematics
6
Precautions to be Observed before Welding
6
Safety Notice
8
Data Plates and Certifications
8
Engine
8
Transmission
9
Drive Axle
9
Front Axle
9
Power Steering Pump
9
Coach Final Record
9
Safety Certification
9
Figure 3: Typical Serial & Model Numbers
9
Figure 4: I - Beam Axle Typical Serial & Model Numbers
9
Figure 5: Power Steering Pump
9
DOT Certification Label
10
Fuel Tank Label
10
Vehicle Identification Number (VIN)
10
Figure 6: Dot Certification Plate
10
Figure 7 : Vehicle I . D
10
Figure 8 : Vehicle Identification Number
11
Fastener Strength Identification
12
Figure 9 : Thread Notation
12
Figure 10: Bolt Strength Markings
12
Standard Torque Specifications
13
Self-Locking Fasteners
15
Recommendations for Reuse
15
Six Lobed Socket Head
15
Figure 11 : Self-Locking Fasteners
15
Figure 12: Metric - Us Standard Conversion Table
16
Figure 13: Conversion Chart
17
Volvo D
27
Figure
27
Volvo D13 Engine
28
System Overview
28
Engine Overview
32
Engine Oil
33
General
33
Oil Quality
33
Oil Change Intervals
34
Oil Filters
34
Synthetic Lubrication
34
Oil Viscosity
34
Oil Additives
35
Oil Consumption
35
Oil Change
35
Oil Filters Change
36
Checking the Oil Level
37
Power Plant Assembly Removal
37
Power Plant Assy. Installation
40
Engine Mounts
41
Electronic Foot Pedal Assembly (Efpa) & Throttle Position Sensor
42
Specifications
43
Fuel System with Volvo D13 Engine
47
Description
47
Fuel Valves
48
Fuel Filters
48
Primary Fuel Filter Replacement
49
Secondary Fuel Filter Replacement
49
Priming the Fuel System
50
Fuel Pump Removal and Installation
50
Fuel Lines and Flexible Hoses
51
Fuel Tank
51
Tank Removal
52
Tank Installation
52
Fuel Tank Verification
52
Polyethylene Fuel Tank Repair
52
Fuel Specifications
53
Fuel Type
53
Blending
54
Biodiesel Fuels
54
Air Cleaner (Dry Type)
54
Pre-Cleaner Servicing
54
Air Cleaner Servicing
55
General Recommendations
55
Air Cleaner Restriction Indicator
55
Fuel Pedal
55
Fuel Pedal Adjustment
55
Potentiometer Replacement
56
Specifications
56
Exhaust Aftertreatment System Overview
60
Maintenance
60
Flexible Coupling Installation
61
Diesel Particulate Filter (Dpf)
61
Catalytic Converter
63
Removal
63
Assembling Catalytic Converter
65
Diffuser Assembly
66
Diffuser Adjustment
66
Maintenance
67
Diesel Exhaust Fluid (Def) Tank and Injection System
67
Diesel Exhaust Fluid
68
Def Tank Cleaning
68
Pump Assembly Filter Element Replacement
69
Aftertreatment Fuel Injector
70
Replacement
70
Torque Specifications
72
Description
79
Maintenance
80
General Recommendations
80
Mta Vehicles Equipped with Volvo D13 Engine
80
Hoses
80
Constant-Torque Hose Clamps on Coolant Lines -Volvo D13
81
Installation
81
Maintenance
81
Constant-Torque Hose Clamps
81
Cac )
81
Thermostat Operation
82
Thermostat Replacement
82
Checking Thermostat
82
Coolant
82
Coolant Level Verification
82
Coolant Level Sensor
83
Thawing Cooling System
83
Cooling System Recommendations
83
Coolant Recommendations for
83
Mta Coaches Equipped with Volvo D 13 Engine
83
Draining Cooling System
84
Filling Cooling System
85
Flushing
85
Cooling System Descalers
86
Reverse Flushing
86
Spin-On Coolant Filter
86
Radiator
87
Maintenance
87
Radiator Removal & Installation
87
Charge Air Cooler Leakage
90
Cooling Fan Drive Mechanism
90
Drive Pulley and Universal Joint Shaft
90
Idler Replacement
91
Variable Speed Cooling Fan
91
Locking Radiator Fan for Emergency Operation
92
Electrical Locking
92
Mechanical Locking
92
Maintenance
93
Inspection
93
Fan Removal Installation
93
General Description
100
Wiring Diagrams
100
Using Wiring Diagrams
100
Testing Circuits
101
Wire Sizes and Colors
101
Spare Wires
101
Cleaning Connectors
102
Circuit Breakers
102
X3-45 Coaches
102
Multiplex Fuses
102
Relays
103
Precautions
103
X3 Series Coach
105
Maintenance
105
Rear Electrical Panel, Junction Panel, Battery Compartment & Equalizer
105
Rear Electrical Panel
106
Rear Junction Panel
106
Battery Compartment
106
Front Electrical and Service Compartment
106
A/C Junction Box
106
Engine Rear Start Panel
107
Entrance Door & Wiper Control Panel
107
Batteries
107
Battery Discharge Protection
108
Main Battery Relays
108
Battery Removal and Installation
108
Battery Rating
109
Battery Maintenance
110
Visual Inspection
110
Removing Surface Charge
110
Testing Battery Cables
110
Battery Charging
111
Emergency Jump Starting with Auxiliary (Booster) Battery
111
Common Causes of Battery Failure
112
Troubleshooting
113
Battery Voltage Warning" Pictogram
113
Voltmeter Gauge Definitions
113
Troubleshooting and Testing the Multiplex Vehicles
113
Electrical System Diagnostic
113
Probing Voltage on the Multiplex Circuits
114
Can Network
114
Spare CAN
114
Multiplex Input Test Mode
114
Test Sequence
116
Forced Activation of the Radiator Fan Clutch
116
Can Network Layout and Troubleshooting
117
Troubleshooting
117
Available Functions
123
Lower Priority Modules for Breakdown Service
123
Multiplex Modules
123
MCM
123
Io-A
123
Io-B
123
Multiplex Modules Replacement
123
Replacing IO-A or IO-B Modules
123
Replacing the MCM Module
124
Bosch Alternators
124
Alternator Brush Replacement
125
Identifying the Defective Alternator
126
Alternator Drive Belt
126
Adjustment
126
Battery Equalizer
126
Battery Charger
126
Power Inverter
127
Starter
127
Exterior Lighting
127
Headlights
127
Headlight Beam Toggle Switch
127
Maintenance
127
Headlight Adjustment
128
Sealed-Beam Unit
129
Front Turn Signal
130
Stop, Tail, Directional, Back-Up, and Hazard Warning Lights
130
Lamp Removal and Replacement
130
Center Stoplights and Center High-Mounted Stop Light (CHSL) Removal and Replacement
130
License Plate Light
130
Clearance, Identification and Marker Lights
130
Clearance and Identification Light Removal and Replacement
131
Interior Lighting Equipement
131
Control Panel Lighting
131
Switch Lighting
131
Telltale Light Replacement
131
Gauge Light Bulb Replacement
131
Stepwell Lights
131
Description
182
Welding Procedures
182
Maintenance
183
Manual Fluid Level Check
183
Cold Check
183
Hot Check
184
Fluid Level Check Using the Pushbutton Shift Selector
184
Importance of
185
Keeping Oil Clean
185
Recommended Automatic Transmission
185
Oil Contamination
186
Metal Particles
186
Coolant Leakage
186
Control System Prognostics
186
Oil and Filter Change Interval
190
Allison Transmission Removal
191
Transmission Oil Cooler Removal
192
Cleaning and Inspection of Allison Automatic Transmission
193
Breather
193
Allison Transmission Installation
193
Allison Automatic Transmission Troubleshooting
194
Diagnostic Troubleshooting Codes (Dtc) - Allison 4Th Generation Controls
195
Diagnostic Codes - Allison 4 Generation Controls
195
Diagnostic
195
Allison
195
Diagnostic Troubleshooting Codes (Dtc) List - Allison
198
Section 09: Propeller Shaft
204
Propeller Shaft
204
Description
204
Removal, Disassembly, Reassembly and Installation
204
Cleaning, Inspection and Lubrication
204
Cleaning and Inspection
204
Lubrication
204
Explanation of Common Damages
206
Troubleshooting
206
Specifications
206
Front Axle
208
Description
208
Lubrication
208
Maintenance
208
Removal and Replacement
210
Removal
210
Replacement
210
Service Instructions for Steer Axle
211
Steering Knuckle (King) Pin Inspection
211
Checking Lateral Slackness
211
Checking Vertical Slackness
212
Front Wheel Alignment
212
Inspection before Alignment
212
Minor Front Wheel Alignment
212
Major Front Wheel Alignment
213
Turning Angle Adjustment
213
Turn Adjustment
213
Hydraulic Stop
214
Front Wheel Camber
214
Camber Check
214
Front Axle Caster
214
Front Wheel Toe-In
215
Inspection and Adjustment
216
Troubleshooting
217
Specifications
218
Torque Specifications
218
Drive Axle
220
Description
220
Drive Axle Lubrication
220
Maintenance
220
Checking and Adjusting the Oil Level
221
Draining and Replacing the Oil
221
Speed Sensors (Anti-Lock Brake System, ABS)
221
Removal and Reinstallation
221
Disassembly and Reassembly
222
Gear Set Identification
222
Adjustments
222
Fastener Torque Chart
222
Tire Matching
222
Drive Axle Alignment
223
Procedure
223
Axle Shaft Sealing Method
224
Tag Axle
225
Unloading Tag Axle
225
Retracting Tag Axle
225
Retracting Tag Axle for Repair Purposes
226
Grease Lubricated Wheel Bearings
226
Removal and Installation
226
Removing Tag Axle Only
226
Removing Tag Axle Along with Suspension Components
226
Removing Transversal Radius Rod
227
Specifications
228
Drive Axle
228
Air System
232
Brakes
232
Air Reservoirs
232
Maintenance
232
Wet (Main) Air Tank
232
Primary Air Tank
232
Accessory Air Tank
232
Secondary Air Tank
233
Kneeling Air Tank
233
Parking Brakes Overrule Air Tank
233
Ping Tank
233
Air System Emergency Fill Valves
233
Accessory Air Filter
234
Filter Element Replacement
234
Cleaning
234
Air Gauges (Primary, Secondary and Accessory)
234
Air Filter/Dryer
234
Air Filter Dryer Purge Tank
235
Haldex Consep Condenser / Separator
235
Maintenance
235
Air Lines
235
Copper Piping
235
Flexible Hoses
236
Nylon Tubing
236
Air Line Operating Test
236
Air Line Leakage Test
236
Maintenance
236
Pressure Regulating Valves
236
Pressure Setting Procedure
237
Air Compressor
237
Compressor Removal and Installation
238
Emergency/Parking Brake Control Valve (Pp-1)
238
Emergency / Parking Brakes Overrule Control Valve (Rd-3)
238
Flip-Flop Control Valve (Tw-1)
239
Dual Brake Application Valve (E-10P)
239
Brake
239
Stoplight Switches
239
Parking Brake Alarm Switch
240
Brake Relay Valve (R-12 & R-14)
240
Quick Release Valves (Qr-1)
240
Spring Brake Valve (Sr-7)
240
Pressure Protection Valve (Pr-4)
241
Low Pressure Indicator (Lp-3)
241
Shuttle-Type Double Check Valve (DC-4)
241
Emergency Bi-Fold Entrance Door Opening Valves
242
Air System Troubleshooting
242
Brake Operation
242
Air Brakes
242
Checking Disc Brake Pads
243
Drive Axle - Equipped with a Solid Rubber Bushing and Exposed Guide Pin
243
Front and Tag Axle - Equipped with L-Bracket Wear Indicator
243
Vehicles Equipped with a Continuous Wear Sensor
243
Brake Pads and Discs Minimal Tolerance Limits
244
Brake Pads
244
Brake Disc
244
Caliper Running Clearance
244
Torque Specifications
245
Safe Service Procedures
245
Air Brake Troubleshooting
246
Maintenance
248
Brake Air Chamber
248
X3-45 Commuter PA1593 DOB 2400-2489
249
Emergency/Parking Brake Manual Release
249
Brake Chamber Removal
249
Brake Chamber Installation
249
Brake Chamber Disassembly
249
Anti-Lock Braking System (Abs)
250
Troubleshooting and Testing
250
Abs Components
250
Electronic Control Unit (ECU)
251
ABS Modulator Valve
251
Sensors
251
Spring Clip
252
Fitting Tightening Torques
252
Specifications
253
Wheels
258
Wheel Maintenance
258
Inspection
258
Single Wheel Removal
258
Single Wheel Installation
259
Dual Wheels
259
Outer Wheel Removal
259
Inner Wheel Removal
259
Inner Wheel Installation
259
Outer Wheel Installation
259
Inspection
259
Wheel Straightness Test
260
Wheel Studs
260
Drive Axle Wheel Studs
260
Front and Tag Axle Wheel Studs
260
Hub Mounted Wheels
261
Care of Wheels
262
Front and Tag Axle Wheel Hubs
262
Hub Bearing Inspection
262
Hub Bearing Removal
263
Hub Bearing Installation
263
Drive Axle Wheel Hubs
263
Bearing Adjustment
263
Disassembly and Repair
264
Tire Maintenance
264
Inflation Pressure
265
Tire Matching
266
Wheel Balancing
266
Tire Rotation
266
Specifications
278
Description
289
I-Beam Axle Front Suspension
289
Air Springs
289
Inspection
289
Removal
290
Installation
290
Shock
290
Inspection
291
Removal
291
Installation
292
Radius Rods
292
Radius Rod Inspection
292
Radius Rod Removal
292
Bushing Removal
292
Bushing Installation
293
Radius Rod Installation
293
Sway Bar
294
Removal
294
Installation
294
Torque Specifications
295
Rear Suspension
299
Air Springs
300
Inspection
300
Removal
300
Installation
301
Shock Absorbers
301
Inspection
302
Removal
302
Installation
302
Radius Rods
303
Rear Underframe Suspension
303
Tag Axle Suspension
304
Torque Specifications
306
Suspension Height Adjustment
307
Height Control Valve
308
Installation
308
Air System
309
Air Tank Maintenance
309
Wet Air Tank
309
Primary Air Tank
309
Secondary Air Tank
309
Accessory Air Tank
310
Kneeling Air Tank
310
Parking Brakes Overrule Air Tank
310
Emergency Fill Valves
311
Vehicle Exterior
318
Vehicle Structure
319
Vehicle Exterior Maintenance
319
Corrosion
320
Preventive Maintenance Schedule
320
Rust
320
Application
323
Common Fiberglass Repair Procedure
325
Repair Using Fiberglass Cloth
325
Repair Using Fiberglass Paste
325
Procedure
326
Common Painting Procedure
327
New Paint Care
327
Paint Touchup
327
Painting
328
Safety
328
Surface Preparation and Paint Application
328
X3-45 Coaches Exterior Finishing and Body Repair
329
Front Bumper
329
Headlights
330
Rear View Mirrors (Rosco)
331
Windshield Wipers
332
Windshield
332
Front Cap
341
Rear Cap
346
Rear Bumper
347
Rear Fender
348
Front Fender
356
Passengers' Area
402
S Section Operation
403
Driver ' S Section
403
Filters
407
Filter
407
Hvac
407
Adding Refrigerant (V Apor State )
415
Evacuating System
415
Charging System
416
Refrigerant System Clean - out after Compressor Failure
417
Compressor
418
Belt Replacement
418
Pulley Alignment
419
Compressor Maintenance
420
Troubleshooting Guide
420
Magnetic Clutch
421
Evaporator Motor
421
Advertisement
Advertisement
Related Products
PREVOST X3-45 2011
PREVOST X3-45 COACH 2018
PREVOST X3-45 Commuter 2020
PREVOST X3-45 COMMUTER 2018
PREVOST X3-45 2017
PREVOST X3-45 2018
PREVOST X3-45 VIP 2015
PREVOST X3-45 VIP 2017
PREVOST X3-45 COMMUTER
PREVOST X3 Commuter
PREVOST Categories
Buses
Motorhomes
Automobile
Automobile Parts
Radio
More PREVOST Manuals
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL